Wire insertion and splicing system including reaction tool

ABSTRACT

A wire termination and splicing system is disclosed and includes a slotted connector block having reaction surfaces for cooperating with a tool and a reaction type tool including an actuator, drive mechansim, a pair of electrically isolated wire insertion members, and a pair of connector gripping members, the actuator being connected to the drive mechanism which includes a full stroke device, the wire insertion members being connected to the drive mechanism and including cutting blades and camming surfaces for cooperating to close the connector gripping members onto the reaction surfaces of the connector, and the connector gripping surfaces including locating teeth to assure proper alignment of the tool on the connector prior to wire installation. An overload mechanism may be included in the drive mechanism to prevent damage to the connector block or the tool due to misuse.

United States Patent [1 1 Caveney et al.

[4 1 May 14,1974

[ l WIRE INSERTION AND SPLICING SYSTEM INCLUDING REACTION TOOL [75]Inventors: Jack Edward Caveney, Chicago; Roy Alleyne Moody, Flossmoor,both of Ill.

[52] US. Cl. 29/203 P [51] Int. Cl H05k 13/04, H0lr 43/00 [58] Field ofSearch 29/203 P, 203 R, 203 D,

29/203 DT, 203 H, 203 MW 56] References Cited UNITED STATES PATENTS9/1971 Halstead 29/203 H 9/ l 97l Primary Examiner-Thomas H. EagerAttorney, Agent, or FirmCharles R. Wentzel, Esq.

Knickerbocker 29/203 H [57 ABSTRACT A wire termination and splicingsystem is disclosed and includes a slotted connector block havingreaction surfaces for cooperating with a tool and a reaction type too]including an actuator, drive mechansim, a pair of electrically isolatedwire insertion members, and a pair of connector gripping members, theactuator being connected to the drive mechanism which includes a fullstroke device, the wire insertion members being connected to the drivemechanism and including cutting blades and camming surfaces forcooperating to close the connector gripping members onto the reactionsurfaces of the connector, and the connector gripping surfaces includinglocating teeth to assure proper alignment of the tool on the connectorprior to wire installation. An overload mechanism may be included in thedrive mechanism to prevent damage to the connector block or the tool dueto misuse.

10 Claims, 27 Drawing Figures k m n l I00 27 5.

WIRE INSERTION AND SPLICING SYSTEM INCLUDING REACTION TOOL I BACKGROUNDOF THE INVENTION The present invention relates to a wire termination andsplicing system and to reaction tools for installing insulated wiresonto a cooperating connector. More particularly, it is directed to asystem including a novel connector and a novel reaction tool forinstalling insulated wires onto insulation stripping contacts, theconnector having reaction surfaces designed to cooperate with thereaction tool.

In the field of telephone wiring systems, insulation stripping orcrushing connectors are widely used for making rapid reliable contactsin junction cabinets be tween specific telephone installations and theincoming lines from the central telephone office. In such connectors, aninsulated wire is normally positioned between a pair of insulationcrushing jaws on a contact and is laterally forced between the jawscausing the deformation and removal of the insulation from the wire bythe action of the jaw surfaces. This type of wire installation isusually effected by means of a punch-like hand tool having a slot forreceiving the tips of the insulation crushing jaws and a pair of wirecontacting surfaces disposed on either side of the slot to engage thewire on either side of the contact. The wire is forced onto the contactmanually by pushing on the fixed handle of the installation tool whichhas no moving parts. The force of the installation is transmittedthrough the contact to the connector block which in the prior art is abulky block of insulated material heavy enough to absorb the force ofthe wire installation.

Newer connectors of the variety referred to as insulation strippingconnectors are becoming miniaturized to the extent that they can nolonger be expected to withstand the force of a conventional wireinstallation operation as described above. In addition, there isincreasing pressure by the industry for improved speed and reliabilityof installation of wire parts onto such connectors. An example of suchan improved miniaturized connector suitable for the rapid installationof 25 pairs of insulated wires is the connector illustrated and claimedin co-pending U.S. Pat. application Ser. No. 225,089, filed of even datewith the present application, entitled Wire Termination and SplicingSystem and assigned to the assignee of the present invention. In theconnector illustrated therein, the contacts are buried in slots slightlywider than the insulated wire diameter, are precisely located within theslots and are made of very thin rendering them somewhat more fragile andsusceptible to mishandling than the heavier prior art contacts. Inaddition, the insulative portion of the connector is normally endmounted and is unsupported in the area where the forces of wireinstallation are applied. A standard wire installation tool as describedabove, would not be suitable for the installation of wires onto such aconnector since it would require proper positioning of the insertionmember in the associated slot to avoid injury to the wire stripping areaof the contact and would cause a bending moment on the body of theconnector between the mounts which might result in damage to theconnector block.

The novel reaction tool described and claimed herein provides a quickand easy means in cooperation with the compatible miniaturized connectorfor positively locating one or more wire insertion members in theappropriate slots of a connector block to prevent damage totheinsulative portion of the connector block or the contact by the wireinsertion member. The reaction tool of the present invention furtherprovides a balanced reactionforce by gripping the contact adjacent thepoint of wire installation and absorbs the force of the wireinstallation through the walls of the slots and back through the body ofthe tool. This reaction type tool thus permits installation of one ormore wires in a connector of the type described without causing abending moment on the connector block and with no net force on themounts of the connector block.

It is an object of the present invention to provide a novel wireinstallation tool.

It is a further object of the present invention to provide an improvedtool for the insertion of wires onto contacts.

Still a further object of the present invention is to provide aself-aligning reaction tool for installing wires onto the contacts of aconnector quickly and efficiently.

These and other objects of the present invention will become clear inconnection with the following detailed description of the inventiontaken together with the drawings in which:

FIG. 1 is a side elevational view of a preferred embodiment of the toolof the present invention ready for installation of a wire onto acompatible connector;

FIG. 2 is a top view of the tool and connector shown in FIG. 1;

FIG. 3 is a front view of a tool embodying the present invention withthe connector gripping members opened;

FIG. 4 is a front view of the tool shown in FIG. 3 with the connectorgripping members in a closed position;

FIG. 5 is a side elevational view of the tool of FIG. I with the housingpartially removed to show the inter ior of the tool in the at restposition;

FIG. 6 is a view similar to FIG. 5 illustrating an intermediate positionof the tool;

FIG. 7 is a view similar to FIG. 5 but illustrating the tool at fullstroke;

FIG. 8 is afragmentary view partly in section taken along lines 8-8 ofFIG. 7;

FIG. 9 is an enlarged fragmentary view of a portion of the tool shown inFIG. 5 in the at rest position;

FIG. 10 is a front view of a tool with the connector gripping membersmisaligned on the connector;

FIG. 11 is a side view of the misaligned tool shown in FIG. 10;

FIG. 12 is a front view of a tool with the connnector gripping membersproperly aligned with a connector in the at rest position;

FIG. 13 is a side view of the aligned tool shown in FIG. 12;

FIG. 14 is a front view of a tool similar to FIG. 11 but showing theconnector gripping members in the closed position;

FIG. 15 is a side view of the tool shown in FIG. 14;

FIG. 16 is a fragmentary sectional view of the front portion of the toolas it is being applied to a connector;

FIG. 17 is a view similar to FIG. 16 showing the connector grippingmembers in a closed position;

FIG. 18 is a view similar to FIG. 17 showing an intermediate position ofinstallation;

FIG. 19 is a view similar to FIG. 18 showing the tool in the full strokeposition;

FIG. 20 is a partial sectional view of an alternative embodiment of thetool of the present invention incorporating a first form of overloadmechanism with the parts in the at rest position;

FIG. 21 is a view similar to FIG. 20 showing the tool in an intermediateinstallation position;

FIG. 22 is a view similar to FIG. 21 illustrating the tool in the fullstroke position, but with the wire insertion member held short of itsfull stroke position and the overload mechanism actuated to accommodatethe same;

FIG. 23 is a fragmentary view of the first form of overload mechanismtaken along line 2323 of FIG. 20;

FIG. 24 is a partial sectional view ofa second alternative embodiment ofthe tool of the present invention incorporating a second form ofoverload mechanism with the parts in the at rest position;

FIG. 25 is a view similar to FIG. 24 illustrating an intermediateposition of the tool;

FIG. 26 is a view similar to FIG. 25 showing a full stroke position ofthe tool but with the wire insertion member held short of its fullstroke position and the overload mechanism actuated to accommodate thesame; and

FIG. 27 is a fragmentary view taken along line 2727 of FIG. 24illustrating the second form of overload mechanism.

DETAILED DESCRIPTION OF THE INVENTION Referring specifically to FIGS. 1and 2, a preferred embodiment of the present invention is illustrated inthe form of a reaction tool 110 positioned to insert insulated wire 32onto a connector 24. In describing the connector, which is the subjectmatter of the previously mentioned co-pending application, the numberingsystem employed for the previous application will be maintained whereverpossible with parts being given like numbers in both applications inorder to facilitate an understanding of the relationship between thetool 110 and the connector 24. The connector 24, as can be seen in FIG.2, includes a series of laterally disposed open-ended slots 86 extendingfrom a central insulative core 85. The central core portion has embeddedwithin it a series of contact strips 27 each of which has a pair ofstripping and gripping areas 70 and 72 (FIG. 16) disposed at oppositeends of the contact strip extending into the slots 86 at theirrespective bases. At the outer lateral extremity of the walls formingthe sides of the slots 86 and symmetrically disposed at opposite ends ofthe slots are a series of reaction surfaces 98 which are formed in theinsulative material of the connector 24 and are each convex in the planview to cooperate with the tool to assure positive location of the toolwith respect to the preselected slots 86 prior to wire installation.Each reaction surface 98 faces toward the central core of the connector24 which is also the direction of wire installation and they form theouter walls of a series of channels 100 each having a U-shaped profileand being adapted to cooperate with the tool 110 during wireinstallation. Further details of the connector 24 will be set forth inconnection with the description of FIGS. 16-19.

Referring now to FIG. 5, a preferred embodiment of the reaction tool 110of the present invention is shown 4 in side elevational view with halfof the housing removed so that the internal mechanism of the tool can beclearly observed. The reaction tool 110, in the illustrated embodiment,comprises a hollow tool body 111 in the shape of a pistol and having acentral cavity. The tool body 111 includes a piston grip portion 112 anda forwardly extending body portion 113. A pivoted handle is mountedwithin the tool body 111 and is positioned adjacent to the piston gripportion 112 for convenient gripping by the fingers of the user. Theupper portion of the handle 130 within the tool body 111 includes an arm133 and a drive leg 134. The arm 133 extends generally at right anglesto the handle 130 and functions to mount a return spring and as part ofa full stroke mechanism for the tool.

A full stroke mechanism including a pivotally mounted pawl is positionedin the upper end of the pistol grip portion of the tool and cooperateswith the arm 133 as will become apparent hereinafter. The drive leg 134is connected to a drive mechanism including connecting rods which are inturn connected to a pair of electrically isolated wire insertion membersor blades so that movement of the handle 130 causes the connecting rods150 to move the insertion member forward with respect to the for-wardlyextending body portion 113 of the tool body 11. A first connectorgripping member is rigidly mounted at the upper outer extremity of theforwardly extending body portion 113 and is adapted to cooperate withthe reaction surfaces 98 on one corner of the connector 24. A secondconnector gripping member 200 is positioned on the lower outer extremityof the forwardly extending body portion 113 and is pivotally mounted sothat its outer tip can move into and out of engagement with anoppositely disposed set of reaction surfaces 98 on the connector 24. Theaforementioned parts are arranged to cooperate so that the movement ofthe handle 130 toward the pistol gripping portion 112 will cause thewire insertion members 160 to move toward the nose of the forwardlyextending body portion 113 and simultaneously cause the second grippingmember 200 to move into a gripping attitude with respect to the reactionsurfaces 98' on the connector 24.

The tool body 111 which is made up of the pistol grip portion 112 andthe integral forwardly extending body portion 113 is hollow and ispreferably made of a suitable insulating material such as a moldableplastic. It can be seen from FIG. 2 that the width of the outerperiphery of the tool is such that it can be easily held by theoperators hand and that the pistol grip portion and the handle arecontoured to comfortably fit the human hand. The forwardly extendingbody portion 113 includes a pair of laterally disposed openings at itsouter tip which act as mounting openings 114 and 1 15 for the first andsecond connector gripping members 180 and 200. At the lower wall of theforwardly extending body portion 113 adjacent the pistol grip 112, ahandle receiving slot 116 is provided with a portion of the slot formedin each of the mating halves of the tool body which, in the illustratedembodiment, are essentially mirror images of each other so that the toolhas a parting line as can be seen in FIG. 2 extending down its center.

The tool body is also provided with an inner partition 117 locatedforward of the handle receiving slot 116 and spaced from the lower wallof the forwardly extending body portion 113 to define on its uppersurface an insertion member guide floor 118 which is planar and extendsfrom the central area of the tool forwardly to the outer extremity ornose of the body portion 113 to provide a flat surface permitting thereciprocal movement of the wire insertion members 160 in response to themovement of the handle 130. An opening in the guide floor 118 isprovided in the forward extremity of the body portion 113 in the form ofa lifter slot 119 the function of which will become apparent inconnection with the detailed description of the insertion members 160and the second connector gripping member 200. In addition to the guidefloor 118, a rectangular open-ended guide channel for the wire insertionmembers is defined by a pair of parallel side walls 125 and a top wall126 which combine in the nose of the tool to provide a rectangularpassage extending forwardly between the connector gripping members 180and 200.

The outer top wall 127 of the tool body is tapered toward the nose toprovide a clear view by the operator of the slots 86 in the connectorduring wire installation. As can be seen from FIG. 1, the operators lineof sight 128 permits visual observation to confirm that the tool 110 isaligned with the proper slots prior to actuation of the tool. Thisfeature prevents the possibility of installing only one of a desiredpair of wires due to misalignment.

At the upper end of the pistol gripping portion 112, the illustratedhalf of the tool body 111 (FIG. 5) is provided with a threaded boss 120which receives a screw 129 (FIG. 1) extending through an opening in theop posite half of the tool body in order to assit in holding the twohalves of the tool is assembly. An additional threaded boss (not shown)is provided at the lower end of the pistol gripping portion to furtherassist in assembling the tool. At the upper extremity of the centralcavity within the pistol gripping portion, a laterally extending pin 12]is positioned extending from the side wall of the cavity in order toaffix and hold the end of a spring which constitutes part of the fullstroke mechanism mentioned earlier. This pin 12] may be formedintegrally with the wall or may be a separate metal pin inserted into anopening in the side wall. A second pin 122 extends from the same sidewall parallel to the first pin and is adapted to mount the pawl 140 ofthe full stroke mechanism for pivotal movement during the operation ofthe tool 1 10. A return spring pin 123 is positioned in the lower end ofthe pistol gripping portion 112 to act as a fixed retainer for one endof a return spring for the handle 130. A large diameter pin 124 whichacts as the handle pivot is positioned to extend between the two sidewalls of the tool cavity in the central area of the handle receivingslot 116 and also may be formed integrally or inserted in a suitableopening.

The handle 130 is formed from a flat sheet of metal such as steel and isformed in one piece which includes a downwardly depending elongatedgripping leg 131, the arm 133 which extends at essentially right anglesto the gripping leg 131 adjacent the pivot and the drive leg 134 whichis formed as an upward extension of the gripping leg beyond the pivotpoint. The gripping leg 131 is covered with a suitable handle grip 132made of rubber or other resilient material in order to facilitateoperation of the tool when held in the operators hand. The handle 130 ismounted on the handle pivot 124 by means of a pivot opening 135 whichextends through the handle at the juncture of the gripping leg 131, thearm 133 and the drive leg 134. V

The drive leg 134 is provided with a drive link opeing 138 at its upperextremity which in the mounted posi tion within the tool body 111 isjust below the top wall midway along the forwardly extending bodyportion 113. The drive link opening 138 provides the connection to theconnecting rods 150 which are in turn connected to the wire insertionmembers 160.

The arm 133 as mentioned earlier, has two distinct functions. It servesas a mount for one end of the return spring by providing an opening 136which receives one hooked end of a return spring 137 the other end ofwhich is hooked over the return spring pin 123 in the pistol grip sothat the action of the return spring tends to cause the handle 130 topivot in a clockwise direction as viewed in FIG. 5 until it reaches theat rest position. The second function of the arm 133 is to act as partof the full stroke mechanism of the tool which assures movement of thehandle 130 through a complete insertion stroke before it can bereleased. In order to perform this function, the outer end of the arm133 is provided with a series of teeth in the form of a ratchet 144which is disposed facing toward the pawl 140 and is adapted to beengaged thereby.

The remainder of the full stroke mechanism includes the pawl 140 whichis mounted on the pin 122 by means of a pivot hole 142 to permit freerotation of the pawl in the plane of the tool handle 130 and the arm133. The pawl 140 further includes a tapered extension which terminatesin a pawl tip 141 having corners suitably shaped to engage the teeth ofthe ratchet 144 as it passes the tip of the pawl during rotation of thehandle 130 about the handle pivot 124. In order to dispose the pawl inthe desired position to act as a full stroke mechanism and to return itto a neutral position when it is not engaged by the teeth of the ratchet144 an eye 145 is provided on the opposite end of the pawl from the tip141. The eye 145 is engaged by the end of a short tension spring 143.The tension spring 143 is in turn hooked over the full stroke spring pin121 at the upper rear-most comer of the cavity of the tool body 11. Ascan be seen from FIG. 5, the tension of the spring 143 acts to keep thepawl in a position of rotation just out of contact with the teeth of theratchet 144 when the handle is in the at rest position. In this positionthe ratchet 144 is positioned beneath the tip 141 of the pawl 140.

The connecting rods are in the form of a pair of metal strips eachhaving a first end 151 connected to the drive leg 134 and a second end152 connected to the wire insertion members 160. The first end 151 andthe second end 152 of each of the connecting rods 150 are offset fromeach other by a central offset portion 153 (FIG. 8) in such a mannerthat the first ends 151 are spaced apart and parallel to each other adistance approximately equal to the thickness of the handle 130. Thefirst ends 151 are each provided with a suitable drive pin opening 154and these openings are positioned on either side of the drive linkopening 138 on the drive leg 134 and the pivotal connection is effectedby means of a drive pin 156 extending through the three openings andsuitably affixed.

The second ends 152 of the two connecting rods 150 are positionedagainst each other due to the offset portions 153 in each of the rodsand each includes a blade pin opening 155. In the assembled tool, thetwo blade pin openings 155 are located so that they are aligned. Thusthe two connecting rods 150 provide a balanced pushing or pulling forceon both the handle and on the wire insertion members or blades 160.

Referring again to FIG. 8, it can be seen that each of the wireinsertion blades 160 consists of a flat, generally rectangular, thinplate of metal such as steel. Each insertion blade 160 is provided witha first blade opening 161 located at the rear end of the blade remotefrom the wire insertion surface and with a second blade opening 162disposed midway along its length.

The forwardmost end of the wire insertion blades 160 constitutes thewire engaging surface 163 which actually makes contact with theinsulated surface of the wire during installation of the wire onto thecontacts of the connector. As can best be seen in FIG. 16, the wireengaging surface 163 is provided with a series of recesses and relievedareas extending into the wire insertion blade toward the second bladeopening 162. The first recess 164 is in the form of a deep slotextending lengthwise into the wire insertion blade 160 and, in theillustrated embodiment, positioned closely adjacent to the upperelongated edge of the wire insertion blade 160. A second recess 165 inthe form ofa shallower slot is positioned midway between the long sidesof the wire insertion blade 160 and extends parallel to the sides to adepth approximately one-half the depth of the first recess 164. A thirdrecess in the form ofa relieved area 166 extending parallel to the othertwo recesses and to a depth approximately equal to the depth of thefirst recessed area 164 is provided adjacent to the bottom long edge ofthe wire insertion blade 160. The relieved area 166 is not cut throughthe blade in the form of a slot but is rather formed as a thinned downsection (FIG. 3) by a pair of shallow grooves positioned backto-back onopposite sides of the blade 160. As will become more apparent inconnection with the later description of the installation of a wire, thefirst recess 164 and the relieved area 166 are to accommodate wireretention structures, built into the walls of the connector slots,during insertion of a wire. The second recess 165 is for the purpose ofaccommodating the end of a buried contact at the bottom of the slotduring insertion of the wire.

The wire engaging surface 163 is further provided with a cutter blade167 disposed adjacent its lower extremity close to the bottom side edgeof the wire insertion blade 160 and extending forwardly from the wireengaging surface 163 so that in all positions of the blade the cutterblade 167 forms the outermost point of the wire insertion blade 160. Itis this cutter blade 167 positioned just below the relieved area 166which receives highest stress during installation of a wire. Thus therelieved area 166 provides added strength to the blade which would notbe provided by an open slot. The underside of each wire insertion blade160 is provided with a triangular cutout having one side perpendicularto the lower edge of the blade to form a blade stop 169 at the forwardend of the blade adjacent the relieved area 166 and a second angled sidecomprising a sloped lifter cam surface 168 extending from the deepestpoint of the blade stop 169 on an angle back to the lower edge surfaceof the wire insertion blade 160.

Each of the wire insertion blades 160 is positioned within therectangular blade receiving channel formed by the guide floor 118, sidewalls 125, and top wall 126. The blades are held in sliding engagementwith the side walls by means of spacers best seen in FIG. 8. As can beseen, the first blade openings 161 in the insertion blades 160 arepositioned on either side of the matched blade pin openings 155 of theconnecting rods and are slightly larger in diameter than these openings.Each first blade opening 161 receives an insulating bushing 172 made upof an insulating collar 173 which is inserted in the opening and aninsulating circular flange 174 which is positioned between therespective wire insertion blade 160 and the adjacent second and 152 ofone connecting rod 150. The outer insulating bushing 172 is positionedin the first blade opening 161 of the opposite blade 160 and is alsopositioned with its circular flange 174 disposed between the blade 160and the respective adjacent second end 152 of the other connecting rod150. All of the aforementioned members are linked together by means of ablade pin 171 which extends through the blade pin openings of theconnecting rods 150 to form a pivotal connection between the connectingrods and the wire insertion blades 160. This structure also provides, atthat point, complete electrical isolation of the right-hand wireinsertion blade from the left-hand wire insertion blade although theyare commonly mounted by means of the common blade pin 171. v

This electrical isolation and spacing is further maintained by means ofa blade spacer 170 (FIG. 8) made entirely of insulating material in theform of a small disc 175 having a pair of short cylindrical stubs 176extending from opposite sides thereof and having a common axistherewith. The disc 175 contacts the facing surfaces of the blades andis of a suitable width to maintain the spacing of the wire insertionblades 160 so that they are positioned against the side walls 125 of theblade channel. The stubs 176 are received in the respective second bladeopenings 162 of the two wire insertion blades 160. Thus, in movement ofthe blades 160 the blade spacer is carried by means of the stubs 176 inthe openings 1 62 to prevent the blades from assuming a spacing lessthan the disc while the walls 125 of the channel set the outer dimensionof the blade spacing so that the blades are provided with a fixeduniform and precise spacing which coincides with the spacing of theadjacent slots 86 on the connector 24.

The reason for maintaining the insertion blades in electrical isolationfrom each other and from the remainder of the metallic parts of the toolis that the wires being installed are installed in pairs and often arein the hot or current carrying condition during installation. Theisolation of the blades 160 thus prevents shorting between wire pairswhile permitting simultaneous pair installation.

The first connector gripping member 180 which, in the illustratedembodiment, is fixed relative to the tool body 111 is mounted on theupper and outer extremity of the forwardly extending body portion 113which has a cutout 196 to fit the inside shape of the gripping member180. The connector gripping member 180 includes a transverse wall 181extending across the top of the tool and a pair of laterally disposedparallel side walls 182 and 183 each having a mounting pin opening 184aligned on opposite sides of the tool body nose with the upper mountingopening 114 and affixed thereto by a mounting pin 194. The transversewall (FIG. 5) is not of uniform thickness and is heavier at its rear endto fit the cutout 196 on the tool body. The

side walls 182 and 183, as can best be seen in FIG. 1, are of a lesserheight atthe outer tip of the tool and increase in height toward themain body of the. tool. This shape causes the transverse or top wall 181to taper downwardly to the front of the tool thus maintaining theoperators line of sight 128 referred to earlier. The outer end of thefirst connector gripping member 180 is formed by a curved transition 185which merges the transverse wall 181 into a front wall 186 best seen inFIG. 3. The front wall 186 is also connected to the side walls 182 and183 so that the overall shape of the connector gripping member 180 ishood-like.

The front wall 186 is, when the tool is held in its normal verticalposition as illustrated in FIG. 1, vertically disposed and terminates ina linear channel engaging edge 187 (FIG. 3) which is adapted to beplaced in the bottoms of the channels 100 described earlier with respectto the connector 24. Consequently, the thickness of the wall 186 is alsoslightly less than the width of the channels 100 so that the firstconnector gripping member can be easily inserted into the channels. Thecentral area of the front wall 186 is provided with a pair ofrectangular notches 188 best seen in FIGS. 3 and 4 spaced on either sideof the vertical center line of the tool a distance equal to half thedistance from-centerto-center on the slots 86 of the connector. Thesenotches 188 are precisely located and are suitably dimensioned to permitthe wire insertion blades 160 to pass through the front wall 186 andinto the slots of the connector 24 during insertion of a wire. The sizeof the notches 188 is selected to avoid any metal-to-metal contactbetween the wire insertion blades 160 and the notches to preserve theelectrically isolated condition of the two blades 160.

The channel engaging edge 187 of the front wall 186 is further providedwith four alignment teeth. The first alignment teeth are a pair ofoutside teeth 189 and 190 extending downwardly from the channel engagingedge 187 as extensions of the front wall 186 and each having a Widthslightly less than the undistorted width of the slots 86 of theconnector 24. A pair of inside alignment teeth 191 and 192are positionedon each side of the pair of notches 188 intermediate the notches and theoutside teeth 189 and 190. Each of these teeth is also formed as anextension of the wall 186 and extends in its plane downwardly in amanner similar to that described with respect to the outside teeth. Theinside teeth 191 and 192 are also of appropriate Width to be snugly buteasily received in the slots 86 of the connector.

Each inner and outer alignment tooth is provided with a radiused tip 195which cooperates with the convex bearing surface 98 described earlier toprovide a self-aligning feature for the tool of the present invention.Each radiused tip 195 has an axis perpendicular to the front wall 186 ofthe connector gripping member 180. The four alignment teeth, as can bestbe visualized from FIGS. 2 and 14, span six slots and are designed to bereceived in two slots on each side of the pair of slots into which thewires are to be installed. As will become apparent hereinafter, if thesealignment teeth are not received into the appropriate slots 86, the tool110 will not properly seat on the connector 24. Thus there is no dangerof installing the wires with the tool misaligned. The back side of thefront wall 186 adjacent the channel engaging edge 187 is flat anduninterrupted and constitutes an elongated. bearing surface 193 facingtoward the tool and adapted to engage five bearing surfaces 98simultaneously with one of the bearing surfaces being positioned betweenthe notches 188 and the remainder of the bearing surfaces positionedbetween the aligment teeth (FIG. 14) to provide a symmetrical reactionforce during installation of the wire and to prevent side-to-sidetwisting of the tool with respect to the connector during wireinsertion.

The second connector gripping member 200 is similar in shape to thefirst connector gripping member 180 and includes a transverse wall 201extending under the nose of the tool, a pair of vertically disposed sidewalls 202 and 203 each having a mounting pin opening 210 aligned withthe lower mounting opening in the nose of the tool. Pivotal mounting ofthe second connector gripping member 200 is effected by means of asuitable mounting pin 211 extending through the opening 115 and throughthe mounting pin openings 210 in the side walls. The underside of thetool nose has a cutout 197 similar to the cutout l96 on the top wall.The transverse wall 201 is of uniform thickness and does not mate withthe cutout 197 thus providing clearance for pivoting of the member 200.As in the case of the first connector gripping member 180, the secondconnector gripping member 200 is provided with a front wall 204 which isconnected to the transverse wall 201 across its front end. The frontwall 201 terminates in a linear upwardly disposed channel engaging edge205. The general shape of the second connector gripping member 200 aswas the case with the first connector gripping member is that of ahooded nose having transverse, side and front walls connected alongtheir respective edges.

The channel engaging edge 205 can best be seen in FIGS. 3 and 4 and isinterrupted by a pair of rectangular notches 209 which are similarlyspaced from the center line similarly dimensioned to the notches 188 inthe first connector gripping member. The notches 209 are also for thepurpose of permitting passage of the lower portions of the wireinsertion blades 160 through the nose of the tool and into therespective slots of the connector without causing electrical contactbetween the insertion blades 160 to be established. The front wall 204is also of a thickness somewhat less than the width of the channels 100in the connector so that the second connector gripping member 200 can beeasily received into the row of channels 100 immediately opposite therow which receives the first connector gripping member 180. The innersurface of the front wall 204 constitutes a flat bearing surface 206disposed toward the tool body and adapted to engage five bearingsurfaces 98 on the connector in symmetrical fashion in the same manneras was described with respect to the bearing surface 193 of the firstconnector gripping member (FIG. 14). The side walls 202 and 203 of thesecond connector gripping member 200 are for the most part quite thickwalled and act as spacers to prevent lateral shifting of the memberrelative to the tool body 111 during pivotal movement of the member 200on the pin 21 1. In the area adjacent the front wall 204, however, eachside wall 202 and 203 is provided with a relieved area 208, best seen inFIGS. 4 and 9, to provide a pair of guiding or stabilizing surfaces 207disposed directly below and having the same width as the outsidealignment teeth 189 and 190 of the first connector gripping member 180.These stabilizing surfaces 297 also assist in the alignment of the toolon the connector as will become apparent hereinafter.

In order to effect the desired movement between the connector grippingmembers 180 and 200 for positioning and removing the tool 110 from theconnector 24 a cam means in the form of a lifter 212 is positioned inthe lifter slot 119 in the lower wall of the nose of the tool and ismounted for sliding vertical movement in the slot 119 between an at restposition (FIG. 9) in which it extends above the insertion member guidefloor 118 and abuts the blade stops 169 of the two wire insertion blades1 60 and the installation position in which it extends from the slot 119 below the lower wall of the tool nose into the cutout 197 inengagement with the inner side of the transverse wall 201 of the secondconnector gripping member 200. Because the lifter 212 engages theunderside of both insertion blades 160 it is made of electricallyinsulative material to maintain electrical isolation of the blades 160.The contact with the member 200 is made at a point on the opposite sideof the mounting pin 211 from the front wall 204, thus causing theconnector gripping member 200 to pivot in a clockwise direction asviewed in FIG. 6 so that the channel engaging edge 205 closes on thechannels 100 beneath the connector 24 to lock the second connectorgripping member 200 in the installation position for the duration of thecycle. This movement of the lifter 212 is accomplished by means of thesloped lifter cam surface 168 engaging the top of the lifter 212 at theinitiation of the installation cycle and quickly forcing the lifter 212into its lowermost position thus rendering the first and secondconnector gripping members 180 and 200 in a closed position with respectto each other. The return of the second connector gripping member 200 tothe open position at the end of the cycle is caused by a compressionspring 213 positioned in a suitable recess in the nose of the tool 110and contacting the transverse wall 201 of the second connector grippingmember 200 on the side of the pin 211 opposite the location of thelifter 212. Thus, when the wire insertion blades 160 are retracted, theaction of the compression spring 213 causes the second connectorgripping member 200 to pivot counterclockwise as viewed in FIG. 9pushing the lifter 212 upwardly in the lifter slot 119 and maintainingengagement of the top end of the lifter 212 with the sloped lifter camsurface 168 until the blade 160 has returned to a fully retractedposition in which the blade stop 169 engages the side of the lifter 212completing the cycle.

It should be understood that although the lower connector grippingmember 200 is illustrated as being movable, it is within the scope ofthe present invention to have either the first connector gripping member180 pivotable or to have both connector gripping members pivotable. Itis also within the scope of the present invention to have alignmentteeth on either or both connector gripping members.

A better understanding of the tool 110 of the present invention will befacilitated by an explanation of the operation of the tool 110 duringthe installation of a wire. In making this explanation, reference willbe made to two sequences of drawings. The first sequence, illustratingthe internal operation of the tool 110 is FIGS. -7 and the second,illustrating the relationship of the tool nose to the connector 24, isFIGS. 1619. Referring first to FIG. 5, the tool 110 is shown in the atrest position with the blades 160 fully retracted and the pawl 140 ofthe full stroke mechanism disengaged from the handle 130. In FIG. 6, thehandle 130 has been rotated counterclockwise on the handle pivot 124through approximately one-half of a full stroke. In this intermediateposition, the pin connections of the drive leg 134 to the connectingrods 150 and to the wire insertion blades 160 have caused the wireinsertion blades 160 to move outwardly with respect to the extremity ofthe nose of the forwardly extending body portion 113. This same movementof the wire insertion blades 160 has already caused the sloped liftercam surface 168 to act downwardly on the lifter 212 causing it to movevertically in the lifter slot 119 to pivot the second connector grippingmember 200 into a closed position for gripping the reaction surfaces ofa connector 24. At the same time, the compression spring 213 has beencompressed on the opposite side of the mounting pin 211 so that thesecond connector gripping member 200 is urged back toward an openposition at any time that pressure is relieved from the upper end of thelifter 212. In FIG. 6, one insertion blade 160 has been removed -to showthe insulative bushing 172 and spacer disc 175.

Also in this intermediate position, the full stroke mechanism has comeinto play and the pawl tip 141 has been displaced in a clockwisedirection from its at rest position by engagement with the teeth of theratchet 144. In this position the spring 143 attached to the pawl 140urges the pawl 140 back toward the at rest position maintaining it inengagement with the teeth of the ratchet 144. The spacing of the ratchet144 from the pivot of the pawl 140 is small enough that the tip 141 ofthe pawl 140 cannot possibly pass over center while in engagement withthe ratchet 144. Thus the lines of force between the teeth of theratchet 144 and the tip of the pawl 141 extend over the top of thecenter line of the handle pivot 124. Thus, even when the handle 130 isreleased by the operator in this position and the action of the returnspring 137 urges the return of the handle to the at rest position, theengagement of the pawl tip 141 with the ratchet teeth 144 prevents theclockwise motion of the handle 130 from occurring.

Referring now to FIG. 7, the tool is shown in its full stroke position.In this position, the wire insertion blades 160 are extendedsubstantially beyond the tip of the tool nose and beyond the first andsecond connector gripping members'180 and 200 corresponding to theposition wherein the wire is fully installed. The significant differencein the internal condition of the tool 1 10 in this view from that of theprior view is the return of the pawl 140 to its at rest position due tothe continued action of the spring 143 and due to the clearance of thepawl tip 141 beyond the lower end of the ratchet 144, thus permittingfree pivotal movement of the pawl 140. In this position, if the operatorlets the handle free, the action of the return spring 137 causesclockwise movement of the handle toward the at rest position. During theintermediate position which is not shown, the ratchet 144 engages thetip 141 of the pawl and displaces it in the opposite rotationaldirection from its at rest position thus assuring completion of thereturn of the handle 130 to the at rest position which again placesparts of the tool 1 10 in the positions shown in FIG. 5.

As a consequence of this return movement, the compression spring 213acts to cause the second connector gripping member 200 to pivot in acounterclockwise manner as the lifter 212 is permitted to return to itsat rest position by the sloped lifter cam surface 168. The

at rest or retracted position of the entire mechanism is established bythe bearing action of the blade stop 169 against the side of the lifter212 which balances the remaining force of the return spring 137. Itshould be obvious to those skilled in the art, however, that many othertypes of stops could be employed at various locations throughout thetool body to further guarantee the at rest position desired.

Referring now to FIGS. 16-19, the nose of the tool 110 is illustrated ina sequence of installation steps in conjunction with the compatiblecooperating conductor 24 described in some detail earlier and in greaterdetail in the aforementioned copending patent application. In FIG. 16, awire 32 is positioned adjacent the wire gripping area 70 of the contactstrip 27 in one of the slots 86 of the connector 24. The walls of theslots are provided at their upper and lower ends with a pair of channels100 as described earlier and a pair of convex reaction surfaces 98 alsoas described earlier. In this view, the wire 32 is held adjacent thestripping and gripping area 70 by means of wire restraining means in theform of protrusions 90 extending from the walls (one wall being shown inFIG. 16)of the slot 86 and spaced above and below the contact strip 27,the distances corresponding to the spacing of the first recess 164 andthe relieved area 166 of the wire 'insertion blades 160 on either sideof the second recess 165 which accommodates the stripping and grippingarea 70 during insertion. Each slot also includes wire retaining meansin the form of projections 92 spaced on one side of the contact strip 27in the slot 86 the same distance toward the end of the slot as are theprotrusions 90. The projections 92 act to hold the installed wire at thebottom of the slot 86. The nose of the tool 110 is positioned at anangle to the connector 24 with the channel engaging edge 187 of thefirst connector gripping member placed in the upper channel 100 in theslot wall. In order for this positioning to be effected the alignmentteeth (shown in phantom) of the first connector gripping member 180 mustbe properly aligned with respect to the slots 86 so that they extendinto the slots 86 as illustrated. Otherwise, the channel engaging edgeI87 cannot seat in the bottom of the channel 100 in the mannerillustrated. It should also be noted with respect to FIG. 16, that thesecond connector gripping member 200 and the wire insertion blades 160are in the at rest position, thus permitting adequate clearance for thelower channel engaging edge 205 to clear the lower end of the slot wallin order to assume the appropriate position for installation of thewire.

In FIG. 17, the wire insertion members 160 have moved slightly to theleft and the sloped lifter cam surfaces 168 have driven the lifter 212downwardly causing the second connector gripping member 200 to pivot tothe closed position engaging the lower channels 100 directly beneath theupper channels 100 and directly beneath the channel engaging edge 187 ofthe first connector gripping member 180. In this position, the wireengaging surfaces 163 and the cutter blades 167 of the wire insertionblades 160 have not engaged the wire, consequently no force is appliedbetween the respective bearing surfaces 193 and 206 of the connectorgripping members and the reaction surfaces 98 of the connector 24 andthe channel engaging edges 187 and 205 v merely rest in the bottom ofthe respective channels 100.

In FIG. 18, the positions of the parts of the tool 110 have changed intwo respects. The wire insertion members 160 have now extended beyondthe nose of the tool 110 so that the wire engaging surfaces 163 are inengagement with the wires 32 as are the tips of the cutter blades 167.In this intermediate position, each wire is just beginning'to be forcedonto the stripping and gripping area and over the wire retainingprojections 92 by the force of the wire insertion blades 160. It canalso be seen that the first recess 164 and the relieved area 166 havealready begun to pass the wire restraining protrusions which due to thepositive positioning of the tool and the respective recesses are leftintact during the passage of the blade for use in installation of otherwires at a later time. Also in this intermediate position, the forceshave built up between the bearing surfaces 98 on the connector 24 andthe hearing surfaces 193 and 206 on the respective first and secondconnector grippingmembers.

In FIG. 19, the wire32 is fully installed and the wire insertion members160 are at their extreme position of extension beyond the nose of thetool 110. The first recess 164 has accommodated the wire retainingprojection 92 in addition to the upper wire restraining protrusion 90,and the second recess has accommodated the tip of the stripping andgripping area 70 without causing destruction thereof. The cutter blade167 has pressed the lower end of the wire 32 against the bottom wall ofthe slot 86 and has passed through the wire at this point severing thefree end.

FIG. 19 illustrates in detail the full stroke and consequently highestforce position of the tool. It can be seen even in this position, thatthe force of installation is absorbed by balanced reaction surfaces 98on the connector 24 and surfaces 193 and 206 on the tool 1 10 providingparallel lines of forces disposed at equal distances on opposite sidesof the contact strip 27.

Upon release of the handle 130, parts of the tool 110 are automaticallyreturned to the at rest position and are ready for another cycle. Itshould be understood with respect to all of the foregoing explanationthat in the preferred embodiment of the tool 110, a pair of wires 32 inadjacent slots 86 are being simultaneously installed by the action oftwo identical and parallel acting wire insertion members 160 and thatthe reaction surfaces and the channels are in fact, rows of discretechannels and reactions surfaces extending along the connector 24 asillustrated in FIG. 2 to provide a balanced reaction force in theside-to-side direction as well as the vertical direction mentioned justabove.

FIGS. 10-15 are a sequence of front and side views illustrating theself-aligning features of the tool 1 10 and the connector 24. In FIGS.10 and 11, the tool is positioned so that the alignment teeth 189, 190,191 and 192 are located directly on the convex bearing surfaces 98rather than being positioned in the slots 86 which would properly alignthe notches 188 and 209 and consequently the wire insertion members withthe desired slots for wire insertion. This misalignment can be readilyseen from FIG. 10 which is taken looking into the jaws of the tool 1 10and at the convex reaction surfaces 98. It should be noted from thisview, that the radiused tips 195 of the alignment teeth form essntiallya point contact with their respective convex bearing surfaces 98, andwith the bottom of the associated channel 100. In this position ofmisalignment, as can be seen from FIG. 11, the alignment teeth whichnormally would go down into the slots 86 and extend below the bottom ofthe channels 100 cannot proceed further than the bottom of the channels100 in the misaligned position. Thus, the tool will not seat properlyand the channel engaging edge 187 of the first connector gripping member100 cannot reach the bottom wall of the channel 100. In this misalignedposition, there is no danger of the connector gripping member 180 and200 being closed allowing the wire insertion members 160 to bepositioned against the outer extremities of the walls of the slots 86since as can be clearly seen from FIG. 11, wherein the connectorgripping members 180 and 200 are in the open position, there is notsufficient room for the lower channel engaging edge 205 which iscontinuous, except for the notches 209, to clear the second ends of theslot walls reaching a position below the lower channels 100. Thus, inthe misaligned position there is no possibility of the tool 110 beinginserted to a point where the handle 130 can be moved closing theconnector gripping members 180 and 200 and moving the wire insertionmembers 160 forward.

In addition to this preventative feature in the event of misalignment,it can be seen that the point-to-point contact between the radiused tip195 of each alignment tooth and the convex surface of the associatedreaction surfaces 98 will upon application of any pressure cause thetool 110 to tend to align in the proper slots 86 by having the alignmentteeth slide off the convex reaction surfaces 98 thus permitting thealignment teeth 189-192 to fall into the appropriate slots 86 and assumethe aligned position of the tool 110 with respect to the connector 24 asshown in FIG. 12. It should be pointed out that the alignment of thetool 110 with respect to the connector 24 requires virtually no efforton the part of the operator beyond an initial attempt to align the tool110 with the respective slots 86 into which the two wires 32 are to bepositioned. The tool 110 will then align itself in the position shown inFIGS. 12 and 13 moving either to the left or to the right depending onthe side to which it is misaligned. In FIGS. 12 and 13 it can be seenthat the alignment teeth 189-192 are positioned respectively in theslots 86 and extend below the bottoms of the channels 100 in engagementwith the sides of the slot walls thus positively positioning the tool110 longitudinally of the connector 24 and assuring the positivealignment of the notches 188 with a pair of slots so that the wireinsertion blades 160 will not interfere with the walls of the slots 86and will properly insert the desired pair of wires 32. It can also beseen from FIG. 13 that in the aligned position with the alignment teeth189-192 extending respectively down into the slots 86 below the base ofthe channels 100, the channel engaging edge 187 rests on the bottom ofthe channels 100 and permits the lower channel engaging edge 205 toclear the lower extremity of the slot walls and position itself directlybelow the lower channel 100 in position to grip the connector 24. Inthis position, the relieved area 208 is positioned directly outside theextremity of the wall of the slot 86 and the stabilizing surface 207,which was described earlier, is partially inserted into the slot 86offering an additional alignment feature prior to the closing of thesecond connector gripping member 200. In achieving the position of FIGS.12 and 13 the alignment teeth 189-192, the edge 187 and the surface 207have all acted as camming and guiding surfaces to promote alignment. InFIGS. 14 and 15, the handle 130 of the tool 110 has been movedsufficiently to cause the lower connector gripping member 200 to assumethe closed position in which the channel engaging edge 205 rests on thefloor of the lower channels and the bearing surface 206 lies against thebearing surfaces 98 on the underside of the connector 24. In thisposition of the connector gripping members 180 and 200 with respect tothe connector 24, the tool is ready for a full cycle insertion of a wire32 or a pair of wires 32 onto the connector 24.

Referring now to FIGS. 20-27, two alternate embodiments of the tool ofthe present invention are illustrated. Each embodiment differs from thetool 110 described with respect to the other figures only in theprovision of an overload mechanism to prevent damage to the connector 24or the tool 110 from an improper usage such as the insertion of a secondwire 32 into the same slot 86 where another wire 32 is alreadypositioned. In describing the alternate embodiments, the same numeralswill be employed as in the earlier description for identical parts withthe subscripts a and b to designate which alternate embodiment is beingreferred to. In the embodiment of FIGS. 20-23, the tool 110a includes anoverload mechanism in the form of a collapsible linkage 220 extendingbetween the drive leg 134a and the first blade openings 161a of the wireinsertion members a. The collapsible linkage 220 is made up of threeflat links best illustrated in FIG. 23. The first link 221 is providedwith a pair of openings 222 and223 adjacent its opposite ends and with asmall spring receiving opening 224 at about its midpoint for anchoringone end ofa flexure spring 235. The first link also includes a tab 225disposed at the end of the link remote from the wire insertion membersadjacent the opening 223 and extending outwardly from the end of thelink to cooperate with a stop on the third link. The opening 222 isconnected to the first blade openings 161a of the two wire insertionmembers 1600 by means ofa blade pin 171a to provide a pivotal connectionsimilar to that shown in FIG. 8.

The second link 226 is also a flat strip of metal containing twoopenings 227 and 228 at its opposite ends. The opening 227 is positionedadjacent the opening 223 of the first link. The third link 229 is astrip of metal similar to the second link and having a pair of opening230 and 231 spaced apart along the link a distance equal to the spacingof the openings 227 and 228. The third link is also provided with aspring receiving opening 232 similar to the opening 224 in the firstlink and a stop 233 formed by bending a tab along one edge of the linkat a right angle to the plane of the third link. The second and thirdlinks are connected to the first link at the opening 223 by means of apin 234 inserted through the openings 227 and 230 of the second andthird links respectively. The second and third links are connected tothe drive leg 134a by means of a pin 156a extending through the openings228 and 231. In this assembled condition, the tab 225 engages the top ofthe stop 233 as can best be seen in FIG. 20 to prevent the pivotalconnection between the respective links made by the pin 234 from beingable to rotate through a full circle. The tab 225 and the stop 233 arepositioned so that when they prevent further movement of the links withrespect to each other, the center line extending through the center ofthe openings 222 and 223 of the first link, as extended would pass abovethe center of the pin 156a where the second and third links areconnected to the drive leg 1340. Thus, the assembly is never permittedto extend to a full 180 angle or dead center along the center lines ofthe respective openings of the collapsible linkage.

The flexure spring 235 is positioned over the top of the linkage andextends from the spring receiving openings 224 to the spring receivingopening 232. In the illustrated embodiment the spring is a straightflexure spring having no coils and extends over the joint formed betweenthe respective links by the pin 234. The spring 235 is at all timesslighty flexed when its ends are in openings 224 and 232; thus it has atendency to force the linkages toward a straight line position andcauses the tab 225 to maintain engagement with the stop 233 under normaloperating conditions of the tool.

In FIG. 20, the tool is shown in the at rest position which is also theposition in which the flexure spring is the controlling force and thetab 225 and the stop 233 are in contact. In FIG. 21, the tool 110a isshown in intermediate position wherein the blade and the wire-insertionmembers 160a are beginning to emerge from the nose of the tool. In thisposition the collapsible linkage 220 is still in the relatively straightposition and the spring 235 is in control of the linkage. If the tool110a is properly aligned and no unusual obstructions are encountered thespring 235 is strong enough that the linkage will maintain this positionthroughout the installation cycle. If, however, the tool 110a should bemisaligned or there should be some obstruction in the slot 86, theoverload mechanism comes into play as illustrated in FIG. 22 in whichthe outer end of the wire insertion members 160a remains inapproximately the same position as in the previous FIG. 21 and the forceof the obstruction against the wire insertion member has overcome thestraightening effect of the spring 235 causing the linkage 220 to buckleor collapse. This feature is particularly useful in connection with thefull stroke mechanism since it permits the handle 130a of the tool toproceed through a full cycle disengaging the pawl tip mm from theratchet 144a and permitting the handle 130a to be returned to the atrest position without damaging either the tool 110a or the connector 24.In the absence of the overload mechanism the full stroke mechanism wouldprevent completion of the handle cycle without the wire insertionmembers 160a themselves going through a full cycle at the same time.

In the second .embodiment illustrated in FIGS. 24-27, a tool'lllllbhaviri'ga s'econdcollapsible linkage 240 working on a differentprincipal is illustrated. In the illustrated embodiment the overloadmechanism is again substituted for the connecting rods 150 of theoriginal embodiment and extends between the drive leg 13412 and the wireinsertion members 16Gb. This embodiment of the overload mechanismincludes atelescoping assembly and a compression spring. The portion ofthe assembly connected to the wire insertion members 16% is a hollowtubular sleeve 241 having a circular central recess 242 extendingthrough part of its length and open at one end. The closed end isprovided with a tab 243 extending from the closed end of the tubularsleeve and having an opening 244 connected to the wire insertion membersby means of a pin 1711b to form a pivotal connection. The walls of thetubular 18 sleeve are provided with a pair of slots 245 disposed onopposite sides of the sleeve 241 and extending part of the way from thebottom of the tubular recess to its open end.

The second member 246 is in the form of a circular rod 247 of a suitablediameter to be slidably received within the tubular recess of the sleeve241. It includes at itsouter end a pin 248 extending laterallytherethrough and into the slots 245 to provide an upper and lower stopfor the telescoping action of the rod 247 within the tubular recess 242.At the opposite end of the rod 247 a yoke is provided in the form of aU- shaped piece of metalrigidly affixed to the end of the rod 247. Thebase 249 of the U is wider than the diameter of the rod 247 and parallelside walls 250 and 251 are spaced apart a sufficient distance to receivethe upper end of the drive leg 134b. The outer end of the legs 250 and251 are provided with openings 252 and 253 which receive a pin l56b toform the pivotal connection with the drive leg l34b.

A compression type coil spring 255 is positioned closely surrounding therod 247 and is compressed between the base 249 of the yoke and the upperrim of the walls of the tubular recess 242. Due to the compressionforces of the spring the linkage is, in its normal position, held in itsfully extended position with the pin 248 against the stop formed by theouter end of the slots 245. The sequence in FIGS. 24, 25 and 26 issimilar to that shown and explained with respect to FIGS. 20-22 andillustrates the tool in the at rest position with the overload mechanismfully extended in FIG. 24, in the intermediate position with theoverload fully extended in FIG. 25, and in the overloaded position withthe H overload mechanism fully telescoped in FIG. 26.

As was the case with the earlier described overload mechanism, thestrength of the spring is such that under normal circumstances a fullinstallation cycle would be completed without any telescoping action ofthe overload mechanism. In the event, however, that the wire insertionmembers 1601: should strike an obstruction preventing their furthermovement, the telescoping of the overload mechanism overcoming the forceof the spring 255 permits the handle b to proceed through a full cyclepermitting the tool l10b to be released without damage to the connector24.

In an illustrative embodiment of the cooperating portions of the wiretermination and splicing system of the present invention, thecenter-to-center spacing of the slots 86 of the connector 24 is 0.120inches, and the width of the slots 86 themselves is 0.05 inches, thelateral dimension of each channel 100 is 0.05 inches and the outer edgeor bearing surface 98 of the channel 100 is spaced 0.05 inches from theadjacent outer edge of the connector 24. The outermost edge of the wirerestraining protrusion 90 is located 0.10 inches from the center line ofthe contact strip 27, is spaced from the opposed protrusions 90 adistance of 0.025 inches and has a width measured in the same directionas the width of the recessed area in the insertion blades of 0.025inches. The projections 92 are also spaced from the center line of thecontact strip 27 to their outermost edge a distance of 0.10 inches andare of the same width 0.025 inches as the wire restraining protrusions.The first connector gripping member includes a center-to-center spacingof the notches 188 and of the alignment teeth 189492 of 0.120 inches.Each of the alignment teeth has a width of 0.046 inches and the frontwall 186 at the channel engaging edge 187 has a thickness of 0.045inches. The width of the notches 188 is 0.060 inches. The secondconnector gripping member 200 also is provided with the notches 209having a center-to-center spacing of 0.l20 inches and each having awidth 0.060 inches. The front wall in the channel engaging edge 205 hasa thickness of 0.045 inches.

The wire insertion member 160 has a thickness of 0.045- inches therecess 164 has a width of 0.040 inches and a depth of 0.250 inches. Therecess 165 has a width of 0.030 inches and the relieved area 166 has awidth of 0.040 inches and a depth of 0.250 inches. The wall thickness ofthe relieved area 166 is 0.020 inches. The spacing from the center lineof the recess 165 to the outer edge of the recesses 164 and 166 is 0.1inches.

It will be evident to those skilled in the art that the relationship ofthe reaction surfaces on the connector and on the tool to the contactsis not limited to the exact geometry shown. In the preferred embodimentof the present invention, the reaction surfaces 98 have been illustratedas being symmetrically disposed with respect to the particular pair ofcontacts 27 onto which a wire or pair of wires is to be installed. It iswithin the scope of the present invention for the geometry of theconnector and the tool to vary so long as certain conditions are met.Two or more reaction surfaces are required to be simultaneously engagedby compatible reaction members on a compatible tool. The balancedreaction forces need not be equal on each reaction surface engaged bythe tool. It is sufficient for the purposes of the present inventionthat the resultant of all reaction forces be essentially equal, oppositeand colinear with the resultant of all insertion forces. It is inherentin such a structure that for a connector having similar contacts andsimilar wires these resultant forces will be located substantiallywithin an area defined by the particular reaction surfaces engaged bythe tool and transverse to the direction or path of wire insertion. Insuch a case, there will be no rotational influence or twisting force onthe connector as a whole nor on the tool outside of the area bounded bythe reaction sur faces even if the reaction surfaces are disposed atdifferent distances from the stripping and gripping area or aredisplaced laterally of each other on the connector block. In otherwords, if the connector block were suspended in mid air within thegripping members of the reaction tool, a wire could be inserted byoperation of the tool with no other force being exerted on theconnector.

It is understood that the present invention is not restricted to thespecific embodiments set forth above in the specification and is limitedonly by the scope of the claims. I

What is claimed is:

l. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand reaction surfaces adjacent to the slots, said reaction toolcomprising a tool body, a connector gripping member mounted on said toolbody and including bearing surfaces contacting the reaction surfaces onthe connector block, a wire insertion member mounted on said body formovement between a retracted position and a wire installed position withrespect to a contact in an associated slot, an alignment tooth on saidconnector gripping member engageable in one of the slots in theconnector block to align said wire insertion member with an associatedslot, and drive mechanism for moving said wire insertion member from theretracted position to the wire installed position to force an associatedinsulated wire onto a contact, thus to cause the contact to strip theinsulation from the wire and to grip the wire to make good electricaland mechanical connection therewith.

2. The reaction tool set forth in claim 1, wherein two alignment teethare provided on said connector gripping member engageable respectivelyin the slots dis posed on both sides of the slot with which said wireinsertion member is to be aligned.

3. The reaction tool set forth in claim 1, wherein a plurality of teethis provided on said connector gripping member and engageable in slotsdisposed on both sides of and adjacent to the slot with which said wireinsertion member is to be aligned.

4. The reaction tool set forth in claim 1, for use with a slotted blockin which the reaction surfaces adjacent to the slots are the walls of achannel on the surface of the block, wherein said connector grippingmember is provided with a channel engaging projection extending into theassociated channel for engagement with the reaction surfaces, and saidalignment tooth is on said channel engaging projection and extendstherefrom and into the associated slot.

5. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand spaced first and second reaction surfaces on the opposite ends ofthe slots, said reaction tool comprising a tool body, first and secondconnector gripping members mounted on said tool body for movementbetween a disengaged position and an engaged position with respect tothe first and second reaction surfaces, a wire insertion member mountedon said tool body for movement between a retracted position and a wireinstalled position with respect to a contact in an associated slot,camming and guiding surfaces on said connector gripping memberscooperating with the first and second reaction surfaces on the connectorblock to align said wire insertion member with an associated slot, and adrive mechanism for moving said connector gripping members from thedisengaged position to the engaged position and for moving said wireinsertion member from the retracted position to the wire installedposition, said drive mechanism rapidly moving said connector grippingmembers to the engaged position gripping said connector to position saidwire insertion member in alignment with a slot and thereafter movingsaid wire insertion member to the wire installed position to force anassociated insulated wire onto a contact, thus to cause the contact tostrip the insulation from the wire and to grip the wire to make goodelectrical and mechanical connection therewith.

6. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand reaction surfaces adjacent to the slots, said reaction toolcomprising a tool body having a pistol grip portion and a forwardlyextending body portion, a connector gripping member mounted on said toolbody and including guide surfaces contacting the reaction surfaces onthe connector block, a wire insertion member mounted on said forwardlyextending body portion for movement between a retracted position and awire installed position disposed forwardly with respect to saidconnector gripping member, an alignment tooth on said connector grippingmember engageable in one of the slots in the connector block to alignsaid wire insertion member with an associated slot, drive mechanism formoving said wire insertion member from the retracted position to thewire installed position to force an associated insulated wire onto acontact, and a handle pivotally mounted on said tool body adjacent tosaid pistol grip portion for engagement by the hand of a user andconnected to said drive mechanism for manual actuation thereof.

7. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand spaced first and second reaction surfaces on the opposite ends ofthe slots, said reaction tool comprising a tool body having a pistolgrip portion and a forwardly extending body portion, first and secondconnector gripping members mounted on the outer end of said forwardlyextending body portion for movement between a disengaged position and anengaged position with respect to the first and second reaction surfaces,a wire insertion member mounted on the said forwardly extending bodyportion for movement between a retracted position and a wire installedposition disposed forwardly with respect to said connector grippingmembers, camming and guiding surfaces on said connector gripping memberscooperating with the first and second reaction surfaces on the connectorblock to align said wire insertion member with an associated slot, drivemechanism for moving said connector gripping members from the disengagedposition to the engaged position and for moving said wire insertionmember from the retracted position to the wire installed position, and ahandle pivotally mounted on said tool body adjacent to said pistol gripportion for engagement by the hand of a user and connected to said drivemechanism for manual actuation thereof, said drive mechanism rapidlymoving said connector gripping members to the engaged position grippingsaid connector to position said wire insertion member in alignment witha slot and thereafter moving said wire insertion member to the wireinstalled position to force an associated insulated wire onto a cal andmechanical connection therewith.

8. A reaction tool for installing insulating wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand spaced first and second reaction surfaces on the opposite ends ofthe slots, said reaction tool comprising a tool body, first and secondconnector gripping members mounted on said tool body for movementbetween a disengaged position and an engaged position with respect tothe first and second reaction surfaces, a wire insertion member mountedon said tool body for movement between a retracted position and a wireinstalled position with respect to a contact in an associated slot, acutting blade mounted on said tool body for movement between a retractedposition and a cutting position with respect to a wire in the bottom ofan associated slot, camming and guiding surfaces on said connectorgripping members cooperating with the first and second reaction surfaceson the connector block to align said wire insertion member and saidcutting blade with an associated slot, and a drive mechanism for movingsaid connector gripping members from the disengaged position to theengaged position and for moving said wire insertion memher from theretracted position to the wire installed position and for moving saidcutting blade from the retracted position to the cutting position, saiddrive mechanism rapidly moving said connector gripping members to theengaged position gripping said connector to position said wire insertionmember in alignment with a slot and thereafter moving said wireinsertion member to the wire installed position to force an associatedinsulated wire onto a contact and moving said cutting blade to thecutting position to trim the insulated wire adjacent to the contact.

9. The reaction tool set forth in claim 8, wherein said camming andguiding surfaces have openings therein for receiving therethrough saidwire insertion member and said cutting blade.

10. The reaction tool set forth in claim 8, wherein said wire insertionmember and said cutting blade are integral with each other.

1. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand reaction surfaces adjacent to the slots, said reaction toolcomprising a tool body, a connector gripping member mounted on said toolbody and including bearing surfaces contacting the reaction surfaces oNthe connector block, a wire insertion member mounted on said body formovement between a retracted position and a wire installed position withrespect to a contact in an associated slot, an alignment tooth on saidconnector gripping member engageable in one of the slots in theconnector block to align said wire insertion member with an associatedslot, and drive mechanism for moving said wire insertion member from theretracted position to the wire installed position to force an associatedinsulated wire onto a contact, thus to cause the contact to strip theinsulation from the wire and to grip the wire to make good electricaland mechanical connection therewith.
 2. The reaction tool set forth inclaim 1, wherein two alignment teeth are provided on said connectorgripping member engageable respectively in the slots disposed on bothsides of the slot with which said wire insertion member is to bealigned.
 3. The reaction tool set forth in claim 1, wherein a pluralityof teeth is provided on said connector gripping member and engageable inslots disposed on both sides of and adjacent to the slot with which saidwire insertion member is to be aligned.
 4. The reaction tool set forthin claim 1, for use with a slotted block in which the reaction surfacesadjacent to the slots are the walls of a channel on the surface of theblock, wherein said connector gripping member is provided with a channelengaging projection extending into the associated channel for engagementwith the reaction surfaces, and said alignment tooth is on said channelengaging projection and extends therefrom and into the associated slot.5. A reaction tool for installing insulated wires on a connector havinga slotted block with wire stripping and gripping contacts in the slotsand spaced first and second reaction surfaces on the opposite ends ofthe slots, said reaction tool comprising a tool body, first and secondconnector gripping members mounted on said tool body for movementbetween a disengaged position and an engaged position with respect tothe first and second reaction surfaces, a wire insertion member mountedon said tool body for movement between a retracted position and a wireinstalled position with respect to a contact in an associated slot,camming and guiding surfaces on said connector gripping memberscooperating with the first and second reaction surfaces on the connectorblock to align said wire insertion member with an associated slot, and adrive mechanism for moving said connector gripping members from thedisengaged position to the engaged position and for moving said wireinsertion member from the retracted position to the wire installedposition, said drive mechanism rapidly moving said connector grippingmembers to the engaged position gripping said connector to position saidwire insertion member in alignment with a slot and thereafter movingsaid wire insertion member to the wire installed position to force anassociated insulated wire onto a contact, thus to cause the contact tostrip the insulation from the wire and to grip the wire to make goodelectrical and mechanical connection therewith.
 6. A reaction tool forinstalling insulated wires on a connector having a slotted block withwire stripping and gripping contacts in the slots and reaction surfacesadjacent to the slots, said reaction tool comprising a tool body havinga pistol grip portion and a forwardly extending body portion, aconnector gripping member mounted on said tool body and including guidesurfaces contacting the reaction surfaces on the connector block, a wireinsertion member mounted on said forwardly extending body portion formovement between a retracted position and a wire installed positiondisposed forwardly with respect to said connector gripping member, analignment tooth on said connector gripping member engageable in one ofthe slots in the connector block to align said wire insertion memberwith an associated slot, drive mechanism for moving said wire insertionmember from the retrActed position to the wire installed position toforce an associated insulated wire onto a contact, and a handlepivotally mounted on said tool body adjacent to said pistol grip portionfor engagement by the hand of a user and connected to said drivemechanism for manual actuation thereof.
 7. A reaction tool forinstalling insulated wires on a connector having a slotted block withwire stripping and gripping contacts in the slots and spaced first andsecond reaction surfaces on the opposite ends of the slots, saidreaction tool comprising a tool body having a pistol grip portion and aforwardly extending body portion, first and second connector grippingmembers mounted on the outer end of said forwardly extending bodyportion for movement between a disengaged position and an engagedposition with respect to the first and second reaction surfaces, a wireinsertion member mounted on the said forwardly extending body portionfor movement between a retracted position and a wire installed positiondisposed forwardly with respect to said connector gripping members,camming and guiding surfaces on said connector gripping memberscooperating with the first and second reaction surfaces on the connectorblock to align said wire insertion member with an associated slot, drivemechanism for moving said connector gripping members from the disengagedposition to the engaged position and for moving said wire insertionmember from the retracted position to the wire installed position, and ahandle pivotally mounted on said tool body adjacent to said pistol gripportion for engagement by the hand of a user and connected to said drivemechanism for manual actuation thereof, said drive mechanism rapidlymoving said connector gripping members to the engaged position grippingsaid connector to position said wire insertion member in alignment witha slot and thereafter moving said wire insertion member to the wireinstalled position to force an associated insulated wire onto a contact,thus to cause the contact to strip the insulation from the wire and togrip the wire to make good electrical and mechanical connectiontherewith.
 8. A reaction tool for installing insulating wires on aconnector having a slotted block with wire stripping and grippingcontacts in the slots and spaced first and second reaction surfaces onthe opposite ends of the slots, said reaction tool comprising a toolbody, first and second connector gripping members mounted on said toolbody for movement between a disengaged position and an engaged positionwith respect to the first and second reaction surfaces, a wire insertionmember mounted on said tool body for movement between a retractedposition and a wire installed position with respect to a contact in anassociated slot, a cutting blade mounted on said tool body for movementbetween a retracted position and a cutting position with respect to awire in the bottom of an associated slot, camming and guiding surfaceson said connector gripping members cooperating with the first and secondreaction surfaces on the connector block to align said wire insertionmember and said cutting blade with an associated slot, and a drivemechanism for moving said connector gripping members from the disengagedposition to the engaged position and for moving said wire insertionmember from the retracted position to the wire installed position andfor moving said cutting blade from the retracted position to the cuttingposition, said drive mechanism rapidly moving said connector grippingmembers to the engaged position gripping said connector to position saidwire insertion member in alignment with a slot and thereafter movingsaid wire insertion member to the wire installed position to force anassociated insulated wire onto a contact and moving said cutting bladeto the cutting position to trim the insulated wire adjacent to thecontact.
 9. The reaction tool set forth in claim 8, wherein said cammingand guiding surfaces have openings therein for receiving therethroughsaid wire insertiOn member and said cutting blade.
 10. The reaction toolset forth in claim 8, wherein said wire insertion member and saidcutting blade are integral with each other.